Valve access conduit assembly and method of installing the assembly

ABSTRACT

The combination of: an underground valve for a supply line and having an underground actuator through which a state of the valve can be changed to control flow within the supply line; and a conduit assembly embedded in ground material and defining an access passage through which above ground access can be obtained to the valve actuator. The conduit assembly has a housing defining a cavity in which at least a portion of the valve resides. The conduit assembly further has a valve base assembly configured to interact with: a) the housing; and b) at least one of: i) the valve; and ii) the supply line to maintain a desired relationship between the housing and the at least one of: i) the valve; and ii) the supply line.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to underground valves, such as utility valvesand, more particularly, to a conduit assembly through which above groundaccess can be gained to a valve.

2. Background Art

Underground valves are used to selectively control utility supply, suchas water, to individual residences and businesses. Each valve istypically situated several feet underground and is accessed through avertical conduit assembly. In one known form, the upper end of theconduit assembly is closed by a cap with a separable plug that isthreaded into place. The plug is separated to produce an entry openingto a passage extending downwardly to the valve. The plug is providedwith a fitting to be engaged by a special tool, which thereby allows alevel of control of access to the valve.

Existing conduit assemblies take a number of different forms. In oneform, a cast housing, with an inverted cup shape, is placed over thevalve and straddles the supply line and valve. The housing continuesupwardly into a conduit, with a length selected so that the cap on theconduit is flush with grade.

In an alternative design, a conduit assembly has a fitting that isthreaded directly to the underground valve. The conduit assembly definesa passage that extends continuously from the valve to an upper accessopening.

With both of the above designs, elongate tools are directed from aboveground through the conduit assembly passages to engage actuators on thevalves. The tools control turning of the actuators in oppositedirections to selectively open and close the valves.

Existing designs have some inherent problems, some of which areaggravated as the parts thereof corrode and/or are otherwise affected byenvironmental conditions.

One such problem involves alignment of the conduit passage with thevalve actuator. This is an issue primarily with systems utilizing astraddling housing that may be permitted to shift relative to a valve tothe point that the valve actuator becomes inaccessible through theconduit assembly passage. This condition may result from a defectiveinstallation, shifting from frost, etc. If valve access is required, theground may have to be removed to allow a worker to get into closeproximity to the valve to effect operation thereof and/or to re-installthe conduit assembly.

Another problem is a result of the manner in which the upper cap andplug, that is a part thereof, are constructed. Typically, the plug ismade from brass so that it is not prone to rusting. The threads on thebrass plug mate with threads on another part of the cap, typically madefrom a dissimilar metal. That other metal is generally prone to rustingor corroding, which could cause the threads to bind, thereby inhibitingturning of the plug for separation. It may become necessary to exert asubstantial torque upon the plug to effect separation thereof. Thistorque may cause another part of the conduit assembly to turn. Dependingupon the particular construction, this turning may inflict damage uponthe conduit assembly, the housing at the bottom thereof, the valve,and/or the supply line. This again is particularly a problem withsystems utilizing a straddling housing that may be turned relative tothe valve and supporting line in a manner that inflicts damage thereto.

When this condition exists, the individual seeking to operate the valvehas the option of either taking exceptional steps to avoid turning ofany other part of the conduit assembly associated with the plug, orgambling that the plug will break free before the failure of any otherpart of the system under a large turning torque.

The former option represents a significant inconvenience, particularlywhen utilities budget very little time for their workers to effectaccess. The latter can have significant consequences, and in a worstcase may necessitate a time-consuming repair that could involvereplacement of one or more system parts. In an extreme case, the valveitself may have to be accessed, which involves digging around theconduit assembly to create an access opening wide enough to allow aworker to repair, or remove and replace, the damaged structure,potentially including the valve.

In the event the valve itself must be replaced, the utility may have toutilize an upstream shutoff that could inconvenience not only theimmediately affected entity, but any entity supplied through aninterconnected conduit network downstream of the shutoff.

The above problems may be aggravated by temperature and other weatherconditions. For example, rain followed by freezing temperatures mayfurther lock the system components and make separation of the accessplug even more difficult.

Another problem that has existed is that it is difficult to engage thevalve operating tool with the underground actuator, particularly withconduit assemblies having a substantial vertical length. To address thisproblem, it is known to utilize extension rods. Such rods haveconnecting ends attached to the valve actuator and a spaced actuatingend that is engageable by an appropriate tool operated from aboveground.

Even with an extension rod incorporated into the system, it may bedifficult for a user to effect engagement of the tool with the actuatingend of the extension rod. To facilitate this process, it is known toprovide a number of bends in the extension rod to keep the extension rodgenerally centered within the conduit assembly. However, incorporatingbends adequate to substantially center the extension rod could result ininterference between the extension rod and conduit assembly as theextension rod is turned around a vertical axis. Thus, this problem haspersisted in spite of past efforts to address it.

A still further problem with conventional systems is that they are proneto tampering by unauthorized individuals. Systems of the above type aredesigned with a balance between allowing workers reasonable access andprecluding unauthorized access. Generally, a casual observer candetermine how a cap is installed. Often, without exceptional effort, anunauthorized person may ascertain the easiest way to remove the cap andthereafter tamper with the underground valve or potentially obstructfuture operation of the valve.

In spite of these inherent deficiencies with existing systems, theindustry has continued to use conventional designs. The industrycontinues to seek out alternative designs that are economicallyfeasible, while being reliable in terms of their operation, regardlessof environmental conditions.

SUMMARY OF THE INVENTION

In one form, the invention is directed to the combination of: anunderground valve for a supply line and having an underground actuatorthrough which a state of the valve can be changed to control flow withinthe supply line; and a conduit assembly embedded in ground material anddefining an access passage with a central axis through which aboveground access can be obtained to the valve actuator. The conduitassembly has a housing defining a cavity in which at least a portion ofthe valve resides. The conduit assembly further has a valve baseassembly configured to interact with: a) the housing; and b) at leastone of: i) the valve; and ii) the supply line to maintain a desiredrelationship between the housing and the at least one of: i) the valve;and ii) the supply line.

In one form, the supply line has a central axis. The housing and valvebase assembly cooperatively extend fully around the central axis of thesupply line.

In one form, the valve base assembly has a curved, upwardly opening seatthat nominally conforms to the at least one of: i) the valve; and ii)the supply line.

In one form, the housing is made from a urethane material and defines astop surface/edge and the conduit assembly has a first conduit part thatis slidable guidingly relative to the housing along the central axis toabut the stop surface/edge.

In one form, the housing has a sleeve. The conduit assembly has a firstconduit part that is slidable guidingly against the sleeve along thecentral axis of the access passage.

In one form, the housing is defined by a base material in which thesleeve is embedded.

In one form, the housing has an inverted U-shaped receptacle thatstraddles at least one of: i) the valve; and ii) the supply line.

In one form, the supply line has a central axis. There are componentscooperating between the valve base assembly and the at least one of: i)the valve; and ii) the supply line that are keyed to limit movement ofthe valve base assembly relative to the supply line along the supplyline central axis.

In one form, the conduit assembly further has a second conduit part thatis telescopingly engaged with the first conduit part.

In one form, the housing and first and second conduit parts are eachmade from a non-metal material.

In one form, the conduit assembly has an entry opening to the accesspassage. The conduit assembly further has a cap that can be selectivelychanged between: a) a first state wherein the cap blocks the entryopening; and b) a second state wherein above ground access can be gainedto the valve actuator through the entry opening and access passage. Thecap is made from a non-metal material.

In one form, the underground actuator is operated by turning around anaxis. The combination further includes an extension rod that extendsupwardly from the underground actuator within the access passage and anextension rod support that is attached to the extension rod and actsagainst a surface bounding the access passage.

In one form, the cap has a cutout/notch formed therein configured toreceive a part of a tool that can be used to pry the cap out of itsfirst state.

In one form, the invention is directed to the combination of: anunderground valve for a supply line and having an underground actuatorthrough which a state of the valve can be changed to control flow withinthe supply line; and a conduit assembly embedded in ground material anddefining an access passage with a central axis through which aboveground access can be obtained to the valve actuator. The conduitassembly has a housing defining a cavity in which at least a portion ofthe valve resides. The housing has an inverted U-shaped receptacle thatstraddles and engages at least one of: i) the valve; and ii) the supplyline. The housing is made from a non-metal material.

In one form, the housing is made from urethane and defines a stopsurface/edge. The conduit assembly has a first conduit part that isslidable guidingly relative to the housing along the central axis toabut the stop surface/edge.

In one form, the housing has a sleeve. The conduit assembly has a firstconduit part that is slidable guidingly against the sleeve along thecentral axis of the access passage.

In one form, the housing is defined by a base material in which thesleeve is embedded.

In one form, the conduit assembly further has a second conduit part thatis telescopingly engaged with the first conduit part.

In one form, the housing and first and second conduit parts are eachmade from a non-metal material.

In one form, the conduit assembly has an entry opening to the accesspassage. The conduit assembly further has a cap that can be selectivelychanged between: a) a first state wherein the cap blocks the entryopening; and b) a second state wherein above ground access can be gainedto the valve actuator through the entry opening and access passage. Thecap is made from a non-metal material.

In one form, the invention is directed to a method of installing aconduit assembly to facilitate controlled access to an actuator on anunderground valve. The method includes the steps of: providing acombination described above; repositioning the housing so that theU-shaped receptacle straddles the at least one of: i) the valve; and ii)the supply line; sliding one end of the first conduit part against thesleeve along the central axis of the access passage; cutting the firstconduit part at a second location so that the first conduit part has aselected length between the one end and the second location;telescopingly engaging the second conduit part with the first conduitpart so that the first and second conduit parts have a desired combinedlength; and compacting material around the conduit assembly.

In one form, the supply line has a central axis. The method ofinstalling a conduit assembly further includes the step ofinterconnecting the housing and the at least one of: i) the valve; andii) the supply line so that the housing and the at least one of: i) thevalve; and ii) the supply line are keyed to limit movement of thehousing relative to the supply line along the supply line central axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic representation of a conduit assembly, according tothe present invention, in an operative state in relationship to a valveassociated with a supply line;

FIG. 2 is a perspective view of a prior art conduit assembly in anoperative state relative to a valve on a supply line;

FIG. 3 is an enlarged, partial, cross-sectional view of the conduitassembly taken along line 3-3 of FIG. 2;

FIG. 4 is an enlarged, fragmentary, exploded, perspective view ofcooperating conduit parts on the conduit assembly in FIGS. 2 and 3;

FIG. 5 is an enlarged, exploded, perspective view of a cap at an upperend of a conduit part on the conduit assembly in FIGS. 2-4;

FIG. 6 is a view as in FIG. 2 of a modified form of prior art conduitassembly in an operative state relative to a valve on a supply line;

FIG. 7 is a schematic representation of cooperating parts on a cap andanother part of an inventive form of the conduit assembly;

FIG. 8 is a view as in FIG. 6 showing a specific form of the inventiveconduit assembly, according to the invention;

FIG. 9 is an enlarged, side elevation view of a first conduit part onthe inventive conduit assembly and showing a portion of a cooperatingsecond conduit part;

FIG. 10 is a view as in FIG. 9 wherein the first conduit part is turnedthrough 90°;

FIG. 11 is an enlarged, cross-sectional view of the conduit parts takenalong line 11-11 of FIG. 10;

FIG. 12 is a cross-sectional view of the first conduit part taken alongline 12-12 of FIG. 10;

FIG. 13 is an enlarged view of a portion of the conduit part within thecircle in FIG. 12;

FIG. 14 is an exploded, perspective view of the components in FIGS.9-13;

FIG. 15 is a flow diagram representation of a method of installing aconduit assembly, according to the invention, to facilitate controlledaccess to an actuator on an underground valve;

FIG. 16 is a view as in FIG. 6 of another form of prior art conduitassembly in an operative state relative to a valve on a supply line;

FIG. 17 is an exploded perspective view of the components shown in FIG.16;

FIG. 18 is an enlarged, perspective view of an upper conduit part on theconduit assembly in FIGS. 16 and 17;

FIGS. 19-21 show the conduit part of FIG. 18 with different defects forwhich repair is required;

FIG. 22 is an enlarged, perspective view of a conventional replacementcap used on the conduit part in FIG. 18 once damage is inflicted;

FIG. 23 is a plan view of the replacement cap in FIG. 22;

FIG. 24 is a cross-sectional view of the replacement cap in FIGS. 22 and23 operatively connected to the upper region of the conduit part in FIG.18;

FIG. 25 is a perspective view of the replacement cap in FIG. 22operatively connected with the conduit part in the condition shown inFIG. 21;

FIG. 26 is a view as in FIG. 25 with the conduit part having the FIG. 20condition;

FIG. 27 is an enlarged, elevation view of the conduit part having thecondition in FIG. 20;

FIG. 28 is a view as in FIG. 27 wherein part of the damaged portion ofthe conduit part is removed preparatory to repair;

FIG. 29 is an exploded perspective view corresponding to that in FIG. 17wherein a repair assembly is used after the conduit part is prepared asin FIG. 28;

FIG. 30 is a view as in FIG. 29 with the parts assembled;

FIG. 31 is an enlarged, perspective view of the cap used on the repairassembly in FIGS. 29 and 30;

FIG. 32 is a side elevation view of the cap in FIG. 31;

FIG. 33 is a bottom view of the cap in FIGS. 31 and 32;

FIG. 34 is a cross-sectional view of the cap taken along line 34-34 ofFIG. 32;

FIG. 35 is a perspective view of a modified form of repair assembly,according to the invention;

FIG. 36 is an enlarged, cross-sectional view of the repair assemblytaken along lines 36-36 of FIG. 35;

FIG. 37 is a bottom view of a cap on the repair assembly in FIGS. 35 and36;

FIG. 38 is a perspective view of a further modified form of repairassembly according to the invention;

FIG. 39 is a cross-sectional view of the repair assembly taken alongline 39-39 of FIG. 38;

FIG. 40 is an enlarged, perspective view of a cap that is part of therepair assembly in FIGS. 38 and 39;

FIG. 41 is a side elevation view of the cap in FIG. 40;

FIG. 42 is a bottom view of the cap in FIGS. 40 and 41;

FIG. 43 is an enlarged, fragmentary, perspective view of a conventionalupper conduit part, as shown in FIG. 2, that is broken off at an upperthreaded portion;

FIG. 44 is a view as in FIG. 43 wherein a conventional repair capassembly has been placed over the fractured conduit part;

FIG. 45 is an exploded perspective view of the components shown in FIG.44;

FIG. 46 is a cross-sectional view of the conduit part with the repaircap assembly taken along line 46-46 of FIG. 44;

FIG. 47 is a perspective view of a conventional tool that is used toturn access caps and cooperate with actuators underground to operatevalves;

FIG. 48 is an enlarged, side elevation view of the actuating tool inFIG. 47;

FIG. 49 is an enlarged, end elevation view of the actuating tool in FIG.47;

FIG. 50 is an enlarged, top view of the actuating tool in FIG. 47;

FIG. 51 is an exploded, perspective view of a further prior art conduitassembly;

FIG. 52 is an exploded, perspective view of a further conduit assembly,according to the present invention;

FIG. 53a is a view as in FIG. 52 with the components assembled;

FIG. 53b is an enlarged view of the portion of the conduit assemblywithin the circle in FIG. 53 a;

FIG. 54 is an enlarged, perspective view of a housing on the conduitassembly in FIGS. 52 and 53;

FIG. 55 is a front elevation view of the housing in FIG. 54;

FIG. 56 is a cross-sectional view of the housing taken along line 56-56of FIG. 55;

FIG. 57 is an enlarged, side elevation view of the valve in FIGS. 52 and53 in relationship to a valve base assembly that cooperates with thehousing shown in FIGS. 54-56;

FIG. 58 is a view as in FIG. 57 from a different perspective;

FIG. 59 is an exploded, perspective view of the valve and valve baseassembly in FIGS. 57 and 58;

FIG. 60 is a flow diagram representation of a method of installing aconduit assembly as shown in FIGS. 51-59;

FIG. 61 is a schematic representation of structure cooperating betweenthe housing and valve and/or supply line to maintain a desiredrelationship therebetween;

FIG. 62 is a cross-sectional view of a prior art conduit assembly withan extension rod connected to a valve;

FIG. 63 is an exploded perspective view of the extension rod and valveas shown in FIG. 62;

FIG. 64 is an exploded perspective view of a modified form of conduitassembly, according to the invention, and with an extension rodincorporated;

FIG. 65 is an exploded perspective view of the components in FIG. 64with the conduit assembly shown separated from the extension rod andvalve and with an extension rod support, that is obscured in FIG. 64,shown in relationship to the extension rod;

FIG. 66 is an exploded perspective view as in FIG. 65 and with theextension rod support assembled and with a modified form of conduitassembly;

FIG. 67 is a partially sectioned view of the components in FIG. 66 in anassembled state;

FIG. 68 is an enlarged, cross-sectional view of the conduit assembly andextension rod in FIG. 67 and showing the extension rod support;

FIG. 69 is an enlarged, perspective view of the extension rod support inFIGS. 64-68;

FIG. 70 is a cross-sectional view corresponding to that in FIG. 56 andshowing a modified form of housing and structure connecting the housingand a lower conduit part on a conduit assembly;

FIG. 71 is a perspective view of a modified form of conduit assemblycap, according to the invention;

FIG. 72 is a side elevation view of the cap in FIG. 71;

FIG. 73 is a reduced, perspective view of a conduit piece with the capin FIGS. 71 and 72 in a closed position;

FIG. 74 is a cross-sectional view of the cap and conduit piece takenalong line 74-74 of FIG. 73; and

FIG. 75 is an enlarged view of the structure within the circle shown inFIG. 74.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In FIG. 1, an exemplary form of the invention is shown in schematicform. A conduit assembly at 10 defines an access passage 12 throughwhich above ground access can be gained to an actuator 14 on anunderground valve 16. The valve 16 is associated with a supply line 18for any flowable commodity, such as gas, water, etc. While one specificform of valve is depicted in embodiments described hereinbelow, theinvention can be used to cooperate with virtually an unlimited number ofdifferent valve configurations offered by different manufacturers. It isconceivable that the supply line 18 could even be capable of electricalconductivity whereby the actuator 14 acts as a switch. The supply line18 may be any supply line, such as one that branches off as part of anetwork that supplies individual residences and/or businesses from amain supply. Through the actuator 14, the state of the valve 16 can bechanged to control flow within the supply line 18. As examples, theactuator may be a simple on/off type arrangement or one that varies flowvolume. As used herein, “valve actuator” is intended to encompass anyunderground component that has different states that might be accessedand changed through a conduit passage, regardless of the nature of thesupply.

The conduit assembly 10 defines an entry opening 20 to the accesspassage 12. The conduit assembly 10 further has a cap 22 that can beselectively changed between: a) a first state wherein the cap 22 blocksthe entry opening 20; and b) a second state wherein access can be gainedto the valve actuator 14 through the entry opening 20 and access passage12. The cap 20 may be fully separated in its second state, though thisis not required.

The components shown in FIG. 1 are represented in schematic form toencompass specific forms, hereinbelow described, as well as variationsthereof that would be apparent to one skilled in the art with theinventive teachings in hand. To understand the significance of thepresent invention, some further details of the prior art, as describedgenerally above, will be explained herein, with the associatedshortcomings.

Existing conduit assemblies are most commonly made with one of twodifferent designs. A first prior art design is shown at 10′ in FIGS.2-5. The conduit assembly 10′ consists of a lower conduit part 24 thatis typically made from cast metal. The conduit part 24 has a steppeddiameter with a smaller diameter portion 26 and a larger diameterportion 28. The larger diameter portion 28 has internal threads 30 thatmate with cooperating threads 32 on a valve 16′.

A separate, upper conduit part 34 is telescopingly engaged with theconduit part 24. The lower end 36 of the conduit part 34 is formed todefine diametrically oppositely projecting locking tabs 38, alignableone each with cutouts 40 in a flange 41 at the upper end 42 of theconduit part 24. With the locking tabs 38 and cutouts 40 angularlyaligned, the conduit parts 24, 34 can be telescopingly engaged to bemovable guidingly relative to each other along a lengthwise axis 44 ofthe conduit assembly 10′. A friction ring 46 is placed within a radiallyinwardly opening undercut 48 on the conduit part 24, acts against anouter surface 50 of the conduit part 34 to frictionally grip the conduitpart 24, and functions to inhibit free sliding movement of the conduitpart 34 relative to the conduit part 24.

The conduit part 24 has diametrically oppositely located ribs 52 eachprojecting radially inwardly at a location circumferentially midwaybetween the cutouts 40 in a circumferential direction. The ribs 52extend over potentially the full axial extent of the conduit part 24.

The upper end 54 of the conduit part 34 has external threads 56 thereon.The threads 56 cooperate with internal threads 58 on a cap 60 that isdesigned to be situated at approximately ground level GL. Morespecifically, the conduit parts 24, 34 are relatively repositioned sothat the combined length L of the conduit parts 24, 34 and cap 60situates the upper surface 62 of the cap 60 at approximately groundlevel GL. The conduit parts 24, 34 can be fixed with a selected combinedlength by turning the conduit part 34 relative to the conduit part 24around the axis 44. As this occurs, the locking tabs 38 wedge forciblyagainst the ribs 52 so as to thereby maintain the conduit parts 24, 34locked against relative axial and angular movement.

With this arrangement, the overall length L of the conduit assembly 10′in the vertical direction is substantially fixed. As a consequence,frost tends to expand compacted material M around the conduit assembly10′ so that it exerts a wedging force between the underside of the cap60 and the supply line 18, or potentially between the underside of thecap 60 and other upwardly projecting surfaces, such as those produced bythe different diameters of, and on, the conduit parts 24, 34. Asmentioned in the Background portion herein, these forces couldcompromise the structure of the conduit assembly 10′ and/or mightinflict damage upon the valve 16′ and/or supply line 18, necessitatingunderground access to the site at which the damage has occurred.

Typically, the conduit part 34 and cap 60 will both be made from metal.The threads 58 on the cap 60 bound an entry opening 64 and part of anaxial access passage 66, extending between the entry opening 64 and thevalve 16′ and, more particularly, an actuator 70 therefor. Aconventional tool 72 has an elongate construction and can be directedfrom above ground through the entry opening 64, into and through thepassage 66, and into engagement with the actuator 70, which can bemanipulated from above ground using the tool 72.

Access to the valve actuator 70 is controlled by a plug 74 that hasexternal threads 76 to engage the internal threads 58 on the cap 60. Aboss 78 with a pentagonal peripheral surface 80 is integrated into theplug 74 to accommodate a special tool 81 that is engaged with the boss78 to controllably turn the plug 74 to tighten and release the same. Theshape of the boss 78 makes it difficult to turn the plug 74 withouthaving the special tool 81 that cooperates therewith, thereby limitingunauthorized access to the valve actuator 70.

Typically, the cap 60 will be made from metal that may be cast, orotherwise formed. The plug 74 is commonly made from a brass material. Asnoted in the Background portion herein, the cap 60 and plug 74 are bothprone to corroding and/or accumulating moisture that may migrate betweenthe threads 58, 76 thereon and freeze at low temperatures. Theseconditions each may cause the plug 74 to lock to the cap 60, whereupontorque applied to the boss 78 and the plug 74 may produce sufficientforces on other parts of the conduit assembly 10′ and/or valve 16′ toinflict damage thereupon.

Damage may also be inflicted by impact forces applied to the upperregion of the conduit assembly 10′ that is exposed above grade. Forexample, equipment employed to cut grass, plow snow, etc., may encounterthe upper region of the conduit assembly 10′ and damage the cap 60and/or bend or fracture one of the conduit parts 24, 34. An exemplaryfracture line that might be created under these circumstances is shownat FL in dotted lines in FIG. 2. Generally, the compacted material Mwill rigidify the conduit assembly 10′ adequately that it is not proneto failing, when impacted, significantly below grade. This problem isaggravated when frost heaves the conduit assembly 10′ to expose anadditional length of the conduit assembly 10′ above ground level GL.Since the upper region of the conduit assembly 10′ is conventionallymade with metal components, there is little flexibility to absorbimpacts, which commonly leads to part failure/fracture.

The other most common configuration of prior art conduit assembly,mentioned above, is shown in FIG. 6 at 10″. The conduit assembly 10″differs from the conduit assembly 10′ primarily in the configuration ofthe conduit part 24″, corresponding to the conduit part 24, andcooperating with the part 34″, corresponding to the part 34. Whereas theconduit part 24 is directly connected to the valve 16′, the conduit part24″ is integrated into a cast housing 82 that fits over a valve 16″ in arelationship whereby it straddles the valve 16″ and the supply line 18.To accomplish this, the cast housing 82 is made with an inverted cupshape with diametrically opposite cutouts 84 (one shown) to accommodatethe supply line 18. With this configuration, the conduit assembly 10″does not fixedly connect to the valve 16″. However, frost heaving maynonetheless damage the conduit assembly 10″ and/or effect misalignmentthereof with the valve 16″ that may necessitate digging to access thesite of failure, that may be a significant distance below ground, andpotentially near or at valve level.

The conduit assembly 10″ also includes the aforementioned cap 60 andplug 74. In the event that the cap 60 and plug 74 lock, torquing theplug 74 may inflict damage upon parts of the conduit assembly 10″therebelow, including potentially turning the cast housing 82 so that itis forced against the supply 18 and/or valve 16″ upon which it mightinflict damage.

Details of one exemplary form of the conduit assembly, according to thepresent invention, as shown schematically in FIG. 1, are shown in FIGS.7-14.

One aspect of the present invention is the specific manner in which thecap 22 and another part 86 of the conduit assembly 10 interact, as shownschematically in FIG. 7. More specifically, a part 88 of the cap 22interacts with the part 86 in a manner whereby the parts 86, 88 arerelatively moved against each other as the cap 22 is changed between theaforementioned first and second states. According to the invention, atleast one of the parts 86, 88 is made from a non-metal material. Asexplained below, in the specific embodiment, the exemplary parts 86, 88are in the form of cooperating threads and both made from a non-metalmaterial. However, this is not a requirement as another relativelymovable parts arrangement might be utilized to selectively block andexpose the entry opening 20 to the access passage 12.

In the specific exemplary form of the conduit assembly 10, the conduitassembly 10 is made up of three separate conduit parts—a first upperconduit part 90, a second conduit part 92, and a third conduit part 94.In its simplest form, the conduit part 90 can be utilized in conjunctionwith a single, separate, lower conduit part to define the access passage12 between the entry opening 20 and the valve 16. However, in thedepicted embodiment, the conduit part 90 is shown in association withthe separate, existing, lower, conduit parts 92, 94, that correspondrespectively to the conduit parts 34″, 24″ shown on the prior artconduit assembly 10″ in FIG. 6.

The first conduit part 90 and second conduit part 92 each has a verticallength along the central axis 96 of the conduit parts 90, 92, 94, andthe access passage 12 is defined cooperatively thereby. The conduitparts 90, 92 are slidable guidingly in a lengthwise direction, oneagainst the other, to change the effective combined length L1 of theconduit parts 90, 92. The conduit part 90 defines the part/threads 86that cooperate with the part/threads 88 on the cap 22. For purposes ofthis disclosure, the cap 22 may be considered to be either separatefrom, or a part of, the conduit part 90.

While different cooperating mechanical components may be provided on theconduit parts 90, 92 to allow relative lengthwise movement therebetween,in the depicted form, the conduit part 92 fits within the conduit part90 to produce a telescoping-type arrangement. The conduit part 92 has agenerally cylindrical outer surface 97 centered on the lengthwise axis96.

The first conduit part 90 has a through opening 98 within which thesecond conduit part 92 is directed. The opening 98 is bounded by aradially inwardly facing surface 100. A plurality, and in this casethree, discrete, elongate, axially extending components/ribs 102 projectradially inwardly from the radially inwardly facing surface 100 toengage the outer surface 97 of the second conduit part 92 and guiderelative sliding movement between the first and second conduit parts 90,92. The interaction of the ribs 102 and surface 100 causes the conduitparts 90, 92 to be frictionally held against relative angular and axialmovement.

Additionally, an annular component/bead 104 projects radially inwardlyfrom the surface 98 adjacent the lower region of the conduit part 90 toengage the outer surface 97 of the second conduit part 92 to establish aseal between the first and second conduit parts 90, 92 to block passageof debris therebetween. The bead 104 preferably extends fully andcontinuously around the axis 96 and also produces frictional holdingforces between the conduit parts 90, 92.

In a preferred form, the first conduit part 90 is designed to translatein a vertical path relative to the conduit part 92, while being guidedtherealong. Once the material M is compacted around the full verticalextent of the conduit assembly 10, the conduit parts 90, 92 are heldtogether additionally by forces from the compacted material M. Undernormal conditions, the embedded conduit part 90 will be held withsufficient force by the compacted material M and the cooperating ribs102 and surface 100 that it will not tend to shift vertically relativeto the conduit part 92. However, under higher forces produced, as byexpanded soil under frozen conditions, a threshold releasing force maybe developed that causes vertical guided shifting of the conduit part 90relative to the conduit part 92, thereby avoiding imparting ofpotentially damaging axial wedging forces upon other parts of theconduit assembly 10.

At the same time, the conduit part 90 is configured so that it will notturn within the compacted material M relative to the conduit part 92 asmight allow separation of the conduit part 90 from the conduit part 92,which in turn might give unauthorized access to the valve 16 from aboveground.

In the broadest sense, this resistance to turning may be produced byvirtually any construction wherein the outer surface 106 of the conduitpart 90 has a non-circular shape, as viewed in cross-section along thelength of the axis 96. In the depicted embodiment, this non-circularouter peripheral surface 106 is produced by including at least one, andas shown at least two, discrete radial projections 108 at/from thesurface 106. The projections 108 are shown in the form of elongate finsat diametrically opposite locations. Each fin 108 has circumferentiallyoppositely facing surfaces 110, 112 that inhibit turning of the firstconduit part 90 within the surrounding compacted material M in whichthey are embedded.

The cap 22 is made integral with a boss 114 to be engaged by a specialtool 116 that may be provided to only authorized personnel. The cap 22may incorporate any type of turning system, of which there are currentlymany in this industry and in other industries, wherein the ability toturn a component is restricted to certain authorized personnel.

By turning the cap 22 in one direction around the axis 96, the cap 22can be tightened through the cooperating threads 86, 88. Oppositeturning allows the cap 22 to be separated from the main body 118 of theconduit part 90. In this embodiment, the body 118 has a radiallyenlarged upper region at 120 that is radially undercut at the topthereof where the threads 86 are formed. A part of the cap 22 nests inthe undercut region with the cap 22 tightened. With the cap 22tightened, an axially facing surface 122 thereon abuts to an axiallyoppositely facing surface 124 on the body 118 to effect a seal that isredundant to that provided by the cooperating threads 86, 88.

In the preferred form, the threads 86, 88 are both made from a non-metalmaterial. However, advantages can be realized by making either one, andnot the other, of the threads 86, 88 from a non-metal material.Preferably, the non-metal material produces an effective seal at thethreads 86, 88.

In the most preferred form, the entire cap 22, and the entire body 118are made from a non-metal material, such as molded urethane. However,the invention contemplates that only selected parts of the cap 22 andbody 118 may be made from non-metal material, such as the preferredurethane composition.

By making the parts from urethane, they are not prone to rusting orcorroding. Further, urethane provides the requisite structural strengthand at the same time is sufficiently flexible that it will flex inresponse to, and absorb, many forces, imparted by torquing and impactthat might cause a failure in metal parts.

To augment the thread holding forces, a plurality of cooperating,discrete components 126, 128 are provided respectively on the body 118and cap 22. In this embodiment, each component 126 is in the form of anaxial projection/nub on the surface 124, with the component 128 in theform of an accommodating, complementary receptacle on the surface 122. Aseries of these cooperating components 126, 128 are provided incircumferentially spaced locations around the axis 96.

These components 126, 128 serve multiple purposes. First of all, theygive the user a feel that the cap 22 is fully tightened. Additionally,they perform a locking function, thereby augmenting the frictionalholding force of the threads 86, 88. Thus, they tend to inhibit turningof the cap 22 relative to the body 118 so as to avoid unintended, andunauthorized, loosening of the cap 22.

By strategically using non-metal compositions for some, or all, of themain body 118, and the cap 22, unwanted locking of parts can be avoided.By making the ribs 102 from a non-metal material, they are not prone tolocking to the outer surface 97 of the conduit part 92 that is typicallymade from metal.

In the depicted embodiment for the conduit assembly 10, the conduitparts 92, 94 are telescopingly engaged, one within the other, to changetheir effective combined length. They may be selectively fixed at a setlength using the locking arrangement described for the conduit parts 24,34 on the conduit assembly 10′. While the effective combined length ofthe second and third conduit parts 92, 94 becomes fixed, the effectivecombined length of the embedded conduit parts 90, 92 is allowed tochange, as under heaving forces produced by frost in the compactedmaterial M.

The conduit part 90 is capable of cooperating with the conduit parts 24,34 on the conduit assembly 10′ in the same manner as it cooperates withthe corresponding components on the conduit assembly 10″. No specificdescription will be made herein of the structure and interaction of thecomponents for that variation.

With the inventive structure, a conduit assembly can be installed by amethod, as shown in schematic form in FIG. 15, to facilitate controlledaccess to an actuator on an underground valve. According to the method,as shown at block 140, a conduit assembly is provided of the typedescribed above. As shown at block 142, second and third conduit partsare placed in operative relationship with an underground valve. As shownat block 144, the combined effective length of the second and thirdcomponents is set and fixed. A cap is operatively connected as shown atblock 146. As shown at block 148, the first conduit part is movedrelative to the second conduit part so that the cap is at the desiredheight, as with the top thereof at grade. As shown at block 150,material is compacted around the conduit assembly with the conduitassembly in its operative state, with the first and second conduit partsremaining slidable guidingly against each other to allow the effectivecombined length of the first and second conduit parts to change afterthe material is compacted around the conduit assembly. Of course, it ispossible according to the invention to fix the relationship of the firstand second conduit parts.

Another form of prior art conduit assembly is shown at 10′″ in FIGS.16-26. The conduit assembly 10′″ is associated with a cast housing 82′″,corresponding to that shown at 82 in FIG. 6. The housing 82′″ straddlesa valve 16′″ associated with a supply 18.

The depicted conduit assembly 10′″ and associated housing 82′″ make upwhat is referred to in the industry as a “buffalo style” system. Forpurposes of understanding the present invention, the focus needs only tobe upon the basic construction of the conduit assembly 10′″, and not onhow it specifically interacts with the valve 16′″. It suffices to saythat the depicted version shows a straddling arrangement correspondingto that in FIG. 6.

As with the conduit assembly 10″, the conduit assembly 10′″ has upperand lower conduit parts 34′″, 24′″, respectively. The conduit parts24′″, 34′″ define an access passage 12′″ with an entry opening 20′″.

Typically, the upper conduit part 34′″ is made from metal with anintegral, enlarged flange 160 around the entry opening 20′″ in which areceptacle 162 is defined for a cast iron cap 164. An undercut, annularseat 165 extends around the entry opening 20′″ and defines a support forthe cap 164.

An integrally formed tab 166 has an upwardly facing surface 168 that isgenerally co-planar with an upwardly facing surface 170 bounding theannular seat 162. With this arrangement, the underside 172 of the cap164 can be facially placed against the surfaces 168, 170 so that the topside 174 of the cap 164 is substantially flush with the top of theflange 160.

The tab 166 has a receptacle 176 that is threaded to receive a threadedanchoring bolt 177 that is made from a brass material.

Typically, with the conduit assembly 10′″ operatively positioned andembedded in ground material, as seen in FIG. 16, the cap 164 can beselectively changed between a first state, as shown in FIG. 16, whereinthe cap 164 blocks the entry opening 20′″, and a second state, as shownin FIG. 17, wherein above-ground access can be gained to the valve 16′″and its associated actuator.

The cap 164 is maintained in its first state by the bolt 177. The bolt177 has a polygonally shaped head 178 to be engaged by a cooperatingspecial access tool 179 to control access to the valve 16′″.

The conduit parts 24′″, 34′″ are telescopingly engaged to cause externalthreads 180 on the conduit part 24′″ to engage internal threads 182 onthe conduit part 34′″ in a manner whereby turning of the upper conduitpart 34′″ relative to the lower conduit part 24′″ around a vertical axis184 changes the combined length CL of the conduit parts 24′″, 34′″ alongthe vertical axis 184. The length is increased or decreased, dependingupon the direction of relative turning.

FIG. 18 shows the upper conduit part 34′″ fully intact. In FIGS. 19-21,different types of damage are shown as typically inflicted upon theconduit part 34′″.

In FIG. 19, the tab 166 has been partially broken off, leaving a void at186 in the tab 166 such that it is not usable to effect anchoring of thecap 164.

In FIG. 20, the entire tab 166 is shown broken off, together with aportion of the flange 160 and a portion of a peripheral wall 188 of theconduit part 34′″. As depicted, a substantial void 190 is created whichis contiguous with a crack 192 in the wall 188.

In FIG. 21, an upper portion of the peripheral wall 188 is broken awaysuch that the entire flange 160 and tab 166 have been removed.

Once one of the conditions shown in FIGS. 19-21 occurs, any securityafforded by the cap 164 is compromised. One option when any of theseconditions occurs is to remove enough of the ground material M to accesssubstantially the full axial length of the conduit part 34′″, to allowits separation from the conduit part 24′″. However, given themetal-to-metal threaded engagement between these parts, they are likelyto be effectively fused and not practically separable in the field,particularly in below freezing conditions when water is frozen betweenthese parts.

As a result, a secondary repair measure has been adopted utilizing areplacement cap 198, as shown in FIGS. 22-26. The replacement cap 198consists of a disk-shaped cover 200 that can be placed against theannular seat 165 with the damaged state as shown in FIGS. 19 and 20,wherein at least part of the flange 160 and seat 165 remain intact.

The cap 198 has a pair of locking arms 202, 204 located at diametricallyopposite locations at the underside of the cover 200. Each locking arm202, 204 is connected to the cover 200 in like fashion. Exemplarylocking arm 202 is mounted by a pin 206 for pivoting movement about ahorizontal axis 208. The pin 206 extends through a pair of depending,flat tabs 210, 212, integral with the cover 200, and also through thelocking arm 202 therebetween. The locking arm 202 has a radiallyinwardly facing cam edge 214.

The locking bolt 216 is threadably engaged with a cam block 218 with anangled cam surface 220 that cooperates with the cam edge 214. Turning ofthe locking bolt 216 in one direction causes the block 218 to movevertically upwardly relative to the cover 200, thereby camming each ofthe locking arms 202, 204 radially outwardly to cause edges 222, 224,respectively thereon, to bear against a radially inwardly facing surface226 bounding the access passage 12′″. The locking bolt 216 has theaforementioned polygonally shaped head 228, included for purposes oflimiting access.

The replacement cap 198 is generally effective for dealing with therepair condition shown in FIG. 19. The replacement cap 198, as used onthe conduit part 34′″ with the condition shown in FIG. 20, leaves asignificant part of the aforementioned void 190 exposed, as seen in FIG.26. Consequently, moisture and solid foreign matter may migrate throughthe void 190 into the access passage 12′″ to eventually build up to thepoint that it may be difficult or impossible to control the valve 16′″from above ground.

The replacement cap 198 is likewise less than fully effective when usedon the conduit part 34′″ with the condition as shown in FIG. 21. Asshown also in FIGS. 21 and 25, a jagged upper edge 230 causes a void/gap232 to be maintained that again permits the ingress of foreign matterthat may be solid or liquid in form.

According to the present invention, and as shown in FIGS. 27-34, theconduit part 34′″ on the conduit assembly 10′″ is modified and used inconjunction with a repair assembly 234 to effect field repair.

In the event that there is a flange 160 on the existing conduit part34′″ remaining partially or fully intact, as shown in FIG. 27, a portionof the length of the conduit part 34′″ at its upper end is removed toeliminate that portion of the conduit part 34′″ having a diameter largerthan the main portion 235 of the wall 188. Typically the removal will beeffected by a cutting step. This exposes an upper edge 236 defined by aremaining portion 238 of the conduit assembly 10′″. As explained below,the edge 236 does not have to be cleanly cut, nor does the entire defecthave to be removed as part of the removed length, as seen in FIG. 28.

The repair assembly 234 consists of a conduit piece 240 that defines anupper entry opening 242 and slides over the top region of the conduitpart 34′″. The conduit piece 240, once engaged with the conduit part34′″, is moved axially guidingly against the conduit part 34′″, makingup part of the remaining portion 238 of the conduit assembly 10′″, tothereby situate the entry opening 242 at a desired axial location,preferably at or adjacent to ground level.

An inside, radially inwardly facing surface 244 bounding that portion ofthe access passage 12′″ defined by the conduit piece 240 may be closelyconformed to the radially outwardly facing surface 246 on the conduitpart 34′″. Alternatively, an arrangement as shown in FIGS. 11 and 12might be utilized. As seen in FIG. 33, radially inwardly projectingcomponents 248, spaced circumferentially around the inside surface 244,may cooperatively engage the radially outwardly facing surface 246 tocause the radially projecting components 248 and radially inwardlyfacing surface 244 to engage so as to frictionally resist relative axialmovement between the conduit piece 240 and conduit part 34′″. Whilethree such components 248 are shown in FIG. 33, a single component 248might be utilized, or a number in excess of three might be utilized.This interaction promotes guiding of the telescopingly engaged conduitpiece 240 and conduit part 34′″. It should be noted that the components248 might be provided on the conduit part 34′″ to engage the surface 242to function in the same manner.

An upper flange 250, within which the entry opening 242 is formed, hasthreads 252 thereon formed around the entry opening 242 to cooperatewith threads 254 on a cap 255 that is utilized to selectively block andexpose the entry opening 242.

In a preferred form, both the cap 255 and the conduit piece 240 are madefrom a non-metal material. One preferred composition is urethane.

In this embodiment, the conduit piece 240 has a plurality of projectingcomponents 256 spaced circumferentially equidistantly around the flange250. While six such components 256 are shown, this number is notcritical—one or more than six might be utilized. The cap 255 has acorresponding number of receptacles 258 at an axially facing undersidesurface 260 that faces axially oppositely to the flange surface 261 uponwhich the components 256 are located. As the cap 255 is tightened, theprojecting components 256 are pressed one each into the receptacles 258so as to resist turning of the cap 255.

A polygonally-shaped turning head 262 is integrally formed with the cap255 to facilitate turning by a matched tool. Again, this construction isdesigned for security purposes.

The cap 255 has a different construction than the cap 164, and by reasonof the molded construction described, makes possible a positive sealbetween the cap 255 and conduit piece 240 at the entry opening 242.

With the above-described construction, ground material M can be removedfrom around the damaged conduit assembly 10′″ adequately to exposeenough of the conduit part 34′″ to allow removal of the damaged flangeregion. The conduit piece 240 can then be slid in place and translatedaxially downwardly to a desired height. By firmly compacting groundmaterial M around the conduit piece 240 after it is assembled,substantial resistance to turning of the conduit piece 240 relative tothe conduit part 34″ is created.

As an alternative to using a conduit piece that surrounds the upperregion of the conduit part 34′″, as seen in FIGS. 35-37, a modified formof conduit piece 240′ can be used with radially outwardly projectingcomponents 256′ that cooperatively engage the radially inwardly facingsurface 264 (FIG. 29) on the conduit part 34′″. The conduit piece 240′and cap 255 cooperatively make up a modified form of repair assembly234′. The cap 255 cooperates with the conduit piece 240′ in the samemanner that the cap 255 cooperates with the conduit piece 240.

With the repair assembly 234′, the conduit piece 240′ is simplytranslated into the conduit part 34′″ under pressure until a downwardlyfacing annular edge 266 thereon abuts to the edge 236 (FIG. 28) formedby cutting away at least the damaged flange 160.

A cylindrical body 267 on the conduit piece 240′ can be cut to anappropriate length in the field so that the cap 255 resides at a desiredheight. The body 267 and cap 255 are both preferably made from anon-metal/urethane material that lends itself to convenient fieldcutting.

A further modified form of repair assembly is shown at 234″ in FIGS.38-42. The repair assembly 234″ utilizes a conduit piece 240″ that isconfigured generally as the conduit piece 240, to surround the upperregion of the conduit part 34′″. Friction/guide components 248″ areutilized for the same purpose as the aforementioned, correspondingcomponents 248, 248′.

There are two primary distinctions between the repair assemblies 234 and234″. First of all, a cap 255′ is snap connected to the conduit piece240″ as opposed to being threaded thereto. To accomplish this, anannular bead 268 is provided around the cap 255′ with an angled edge270. As the cap 255′ is pressed downwardly, the bead 258 is deformed asthe edge bears against a surface 272 surrounding an entry opening 274.With the cap 255′ fully seated, the deformed bead 258 aligns with acomplementarily-shaped receptacle 276 into which the bead 268 springs.The bead 258 blocks axial movement of the cap 255′ and therebyreleasably maintains the connection between the cap 255′ and conduitpiece 240″. The cap may be pried off when access to an associatedunderground valve is needed.

The second difference resides in the provision of an annular sealingcomponent 278 on the cap 255′ that fits in a complementary receptacle280 with the cap 255′ fully seated. With the cap 255′ placed operativelyupon the conduit piece 240″, the sealing component 278 is pressed intothe receptacle 280.

It is contemplated that this sealing arrangement might be utilized inany of the other embodiments, such as on the repair assembly 234′.

Preferably, the conduit piece 240′″ and cap 255′ are made from anon-metal/urethane material.

Referring to FIGS. 5 and 43-46, another commonly recurring fieldcondition is depicted, together with conventional structure utilized toeffect on-site repairs. Frost heaving and/or impact may cause thethreads 56 on the conduit part 34 to break off in or below the cap 60,as shown in FIG. 43.

A repair cap assembly 300 has a cylindrical sleeve 302 with a cap 304formed integrally therewith. The repair cap assembly 300 is typicallymade from cast metal. The upper region of the repair cap assembly 300has the same general configuration as the cap 60, including internalthreads 305 to mate with the external threads 76 on the plug 74.

The sleeve 302 has an inside surface 306 that can be slid guidinglydownwardly against the outside surface of the conduit part 34 until anupper edge 308, defined by the fractured conduit part 34, abuts an edge310 defined by a step between the inside surface 306 and a smallerdiameter region at which the threads 305 are formed.

Set screws 312 are directed one each through vertically spaced, radialbores 314 which are threaded to engage external threads 316 on the setscrews 312. By tightening the set screws 312, the repair cap assembly300 can be fixed at a desired vertical height relative to the conduitpart 34.

Replacement of metal parts with metal parts, in the system shown inFIGS. 44-46, reintroduces the aforementioned problems, among which arethe potential fusion between the plug 74 and repair cap assembly 300.

With the conventional cap 60, shown in FIG. 5, and the repair capassembly 300, a full diameter slot 318, 319 is formed to accommodate aturning tool. In each of the inventive embodiments in which a non-metalcomponent is turned to access the passage 12, alternative turningarrangements are contemplated. While the use of a slot 320 (FIG. 8),corresponding to that shown at 318 and 319, is contemplated, morepreferably, the turning may be effected by using, in each inventiveembodiment, a polygonally-shaped turning head, as shown at 262 in FIG.31, and/or spaced openings 323, 324, which cooperate with an actuatingtool, as shown at AT in FIGS. 47-50. The tool AT is a multi-purpose toolwith a conventional construction.

More particularly, the tool AT has an elongate handle 325 which connectsto an operating head 326. The operating head 326 is elongate and forms a“T” shape with the length of the handle 325. The operating head 326 hasat one of its lengthwise ends a fitting 328 with a polygonal receptacle330 to make keyed connection to the turning head 262.

At the opposite lengthwise end of the operating head 326, a “Y”-shapedfitting at 332 is formed with spaced prongs 334, 336 that can be placed,one each, in one of the openings 323, 324. With the prongs 334, 336seated in the openings 323, 324, the elongate handle 325 can bemanipulated to produce the desired directional torque upon the cap 255.Alternatively, the fitting 326 can be engaged and used to turn the head262 in the same manner.

At the end of the elongate handle 325, remote from the operating head326, a separate fitting 338 is provided to engage the actuator 14 on thevalve 16 to effect turning thereof. The T-shaped arrangement of theactuating tool allows the operating head 326 to be grasped andmanipulated to turn the elongate handle 325 about its lengthwise axis tooperate the valve 16.

The cap depicted in FIG. 31 is exemplary only of the other caps shownherein, and others that could be devised by one skilled in the art withthe present invention in hand, that could be operated through a liketool AT.

With all embodiments, the incorporation of non-metal componentsminimizes the likelihood of extensive damage to the conduit assembliesresulting from impacts and other forces imparted at the exposed, upperregions of the conduit assemblies. These forces may be imparted by lawnmowing equipment, plows, etc. Urethane components will tend to absorbthese otherwise potentially damaging forces and may flex or fail withouttransmitting damaging forces to other parts of the conduit assemblies,and particularly those made from metal. Metal parts, and primarily thosereinforced below grade, are thus less likely to be damaged.

In FIG. 51, another existing form of conduit assembly is shown at 10 a″with the same general construction as the conduit assembly 10″, shown inFIG. 6. A housing 82 a is made from a molded, hard plastic material thatis bonded to a conduit part 24 a″, which is also made from plastic. Asmaller diameter conduit part 34 a″ is made from plastic andtelescopingly engaged with the conduit part 24 a″ for controlled lengthadjustment. A cast iron sleeve/top 400 is fixed to the conduit part 34″and is engaged by a releasable cap 60 a made from brass or cast iron, asdescribed above.

While the use of the plastic conduit parts 24 a″, 34 a″ eliminates someof the issues associated with the conduit assembly 10″ shown in FIG. 6,this design still has significant limitations. The top 400 and cap 60 aremain subject to corrosion and fusion. The hard plastic housing 82 atends to be somewhat brittle, particularly when cold, and may not bevery durable. It is thus prone to breaking, particularly when it isturned unrestrained against the valve 16″ and/or the supply line 18.

A further modified form of conduit assembly, according to the presentinvention, is shown at 10 ^(4′) in FIGS. 52-59, and addresses at leastthese latter issues. The conduit assembly 10 ^(4′) cooperates with avalve 16 ^(4′) on a supply line 18 that has a central axis 410. Theconduit assembly 10 ^(4′) performs the same general function as thoseconduit assemblies described above with the conduit assembly 10 ^(4′) inplace and ground material compacted therearound. That is, an accesspassage 12 ^(4′) is defined by the conduit assembly 10 ^(4′) throughwhich above ground access can be obtained to, in this case, a turnableactuator 412 on the valve 16 ^(4′).

In this embodiment, the conduit assembly 10 ^(4′) consists of threesub-assemblies, namely: a) a housing 82 ^(4′); b) a first conduit part92 ^(4′), corresponding to the aforementioned second conduit part 92;and c) a second conduit part 90 ^(4′), corresponding to the upperconduit part 90 as shown in FIGS. 9-14, and described hereinabove.

While the second conduit part 904 can have a construction that isdifferent than the conduit part 90, for purposes of simplicity, theconduit part 90 ^(4′) will be considered to have the same constructionas the conduit part 90.

The conduit part 92 ^(4′) is shown as a single length of non-metal pipe,such as PVC, ABS, etc., with a diameter at its upper end 414 that isselected to telescopingly move within the conduit part 90 ^(4′) tothereby vary a combined length of the conduit parts 90 ^(4′) and 92^(4′). Throughout the description herein, the reference to non-metalpipes/conduits is intended to encompass PVC, ABS, and other non-metalmaterials used conventionally in this, and like applications.

The housing 82 ^(4′) has a body 416 with a generally squared bottomregion at 418 that blends into an outturned base flange 420 with abottom surface 422 that supports the housing 82 ^(4′). The body 416 hasa middle region 424 that tapers from the bottom region 418 to acylindrical top region 426.

The housing 82 ^(4′) may be used either by itself or in conjunction withan optional valve base assembly 428.

The housing 82 ^(4′) has a generally hollow construction to make up abottom region of the access passage 12 ^(4′), which is defined by acavity 430 within the housing 82 ^(4′). In this embodiment, the cavity430 is bounded by opposite wall pairs 432, 434; 436, 438. The walls inthe wall pair 436, 438 are longer in a circumferential direction so thatthe bottom region 418 has an overall rectangular shape as viewed alongthe vertical axis 440 of the housing 82 ^(4′).

The cavity 430 is dimensioned to accommodate the valve 16 ^(4′), adiscrete length of the supply line 18, and the valve base assembly 428,as hereinafter described. To accommodate the valve 16 ^(4′) and supplyline 18, the walls 436, 438 have downwardly opening U-shaped surfaces442, 444, cooperatively defining an inverted U-shaped receptacle 446that straddles at least the valve 16 ^(4′) and, as depicted, the valve16 ^(4′) and supply line 18. The straddling relationship may be with orwithout direct contact. At least a portion of the valve 16 ^(4′) resideswithin the cavity 430. By itself, the housing 82 ^(4′) may be configuredto contact and interact with the valve 16 ^(4′) and/or supply line 18 tomaintain a desired relationship therebetween.

A more positive interaction between the housing 82 ^(4′) and valve 16^(4′)/supply line 18 can be maintained utilizing the valve base assembly428. The valve base assembly 428 is designed to nest conformingly withinthe cavity 430 in the portion thereof defined at the bottom region 418of the body 416. The valve base assembly 428 has a curved, upwardlyopening seat 448 that nominally conforms to the valve 16 ^(4′).Depending upon the precise configuration of the valve 16 ^(4′), the seat448 may also conform nominally to the supply line 18 extending away fromthe valve 16 ^(4′).

In this embodiment, the valve 16 ^(4′) has a discrete portion 450projecting radially oppositely from the central valve axis 452 in theregion beneath the actuator 412. The discrete portion 450 projectsadequately outwardly from the lower region of the valve body 454 suchthat it can nest in a complementarily-shaped receptacle 456 defined inthe valve base assembly 428. By seating the discrete portion 450 in thereceptacle 456, the valve 16 ^(4′) and valve base assembly 428 interactand become keyed together to maintain a desired relationship between thehousing 82 ^(4′) and the valve 16 ^(4′), and thus the supply line 18.Through this arrangement, movement of the housing 82 ^(4′) relative tothe valve 16 ^(4′) and supply line 18, along their respective axes 452,410, is blocked—if not completely, to within a limited range.

The invention contemplates virtually an unlimited number of differentcomponents that might interact between the valve base assembly 428 andone or both of the valve 16 ^(4′) and supply line 18 to maintain adesired relationship therebetween.

With the described embodiment, once the valve base assembly 428 isengaged with the valve 16 ^(4′) and directed into the cavity 430, therelationship between the housing 82 ^(4′) and the valve 16 ^(4′) becomessubstantially fixed, with the axis 440 of the top region 426 generallyaligned with the valve actuator 412. In this relationship, the housing82 ^(4′) and valve base assembly 428 cooperatively extend fully aroundthe axis 410 of the supply line 18 and the axis 452 for the valve 16^(4′).

To accommodate the lower end 458 of the conduit part 92 ^(4′), asleeve/bushing 460 is provided at the top region 426 of the housing 82^(4′). The lower end 458 of the conduit part 92 ^(4′) can be translatedguidingly along the axis 440 into the sleeve/bushing receptacle 462 andsuitably secured. Of course, the male/female relationship of these partsmight be reversed.

In one preferred form, the body 416 of the housing 82 ^(4′) is made froma molded urethane material. The sleeve/bushing 460 is made from a PVCmaterial and is molded into the urethane at the top region 426 of thehousing 82 ^(4′).

The conduit part 92 ^(4′) might be made from the PVC material and bondedto the sleeve/bushing 460 using conventional means/adhesives.

In a preferred form, all of the components making up the conduitassembly 10 ^(4′) —including the housing 82 ^(4′), the sleeve/bushing460, the conduit part 92 ^(4′), and the conduit part 90 ^(4′), togetherwith the cap 2—are made from non-metal materials, and preferably thosedescribed above.

With the structure as described, a method of installing a conduitassembly to facilitate controlled access to an actuator on anunderground valve can be performed as shown in flow diagram form in FIG.60.

As shown at block 464, a conduit assembly, as described above, isprovided.

As shown at block 466, the housing is repositioned so that the U-shapedreceptacle defined thereby straddles at least one of a valve and asupply line.

As shown at block 468, one end of the first conduit is slid guidinglyagainst and relative to the housing, and specifically the sleevethereon.

As shown at block 470, the first conduit is cut at a second location sothat a first conduit has a selected length between the one end and thesecond location. The first conduit can be formed with the desired,predetermined length ahead of time or on site. If the latter iscontemplated, the first conduit length can be selected to project aboveground level for virtually every contemplated field condition, wherebyit can be cut by installers to accommodate a cap that ends up flush toground level.

As shown at block 472, the second conduit is telescopingly engaged withthe first conduit to produce a desired combined length.

As shown at block 474, ground material is compacted around the conduitassembly to complete the construction.

In the event that the valve base assembly 428 is used, the process mayfurther include the step of interconnecting the housing 82 ^(4′) and theat least one of the valve 16 ^(4′) and supply line 18 utilizingcooperating structure 476, 478, respectively on the housing 82 ^(4′) andone of the valve 16 ^(4′) and supply line 18, as shown in schematic formin FIG. 61. Through this arrangement, the housing 82 ^(4′) and at leastone of the valve 16 ^(4′) and supply line 18 become keyed to limitmovement of the housing 82 ^(4′) relative to the supply line 18 alongthe supply line central axis 410.

Certain additional improvements over the prior art are describedhereinbelow.

In FIGS. 62 and 63, the aforementioned prior art conduit assembly 10′ isshown with an associated extension rod 500 connected to, and extendingupwardly from, the turnable actuator 412 on the valve 16 ^(4′).

The rod 500 has a lower, connecting end 502 and an upper, actuating end504. The connecting end 502 has an inverted, U-shaped connector 506 thatstraddles a block-shaped piece 508 on the top of the actuator 412. Withthe connector 506 operatively connected to the actuator piece 508, a pin510 can be directed through the connector 506 and connector piece 508 toeffect securement of the parts 506, 508. In this state, an elongate body512 on the extension rod 500 can be turned around its vertical axis 514,thereby causing a corresponding turning of the valve actuator 412.

The extension rod body 512 has a vertical length that causes theactuating end 504 to reside at least within a couple of feet of the topof the conduit assembly 10′. This allows a person to operate the valve16 ^(4′) utilizing a shorter tool 72. At the same time, thisconfiguration makes it easier for a user to engage a connector 516 onthe tool 72 with a connector 518 at the actuating end 504 of theextension rod 500. As depicted, the connector 518 has a polygonal shapeto make a keyed connection with the connector 516, that may have acomplementary shape.

To further assist engagement of the extension rod connector 518 with thetool 72, the extension rod body 512 is provided with a number of bends520 that cause the body 512 to have an effectively larger diameter sothat it remains somewhat centered within the conduit assembly 10′. It isimpractical to attempt to form the bends 520 so that the extension rod500 is precisely centered within the conduit assembly 10′. Otherwise,the extension rod 500 would tend to bind with the conduit assembly 10′as it is turned.

To effect more precise centering, at least one extension rod support 522is utilized as shown in FIGS. 64-69, with the extension rod 500connected to the valve 16 ^(4′) through the conduit assembly 10 ^(4′) ineach of FIGS. 66-68, and in a modified form thereof in FIGS. 64 and 65.

As seen in FIGS. 66-69, the extension rod support 522 has a body 524with a generally star-shaped construction with a core part 526 with acentral axis 528 from which five separate parts 530 project radiallyoutwardly at regular angular intervals around the axis 528. Each of theparts 530 has a generally rounded free end 532.

The core part 526 has a through opening 534 bounded by a surface 535that surrounds and firmly embraces the outer surface 536 of a straightlength portion 538 of the extension rod 500.

In a preferred form, the thickness t and material of construction forthe extension rod support 522 are selected to allow the actuating end504 of the extension rod 500 to be advanced through the opening 534 toallow the extension rod support 522 to advance over the length at whichthe bends 520 are formed to reside at the straight length portion 538.The selected thickness t depends upon the flexibility of the particularmaterial.

In one preferred form, the extension rod support 522 is made from aurethane material. The thickness t may be on the order of 0.25 inch toone inch or more. One or multiple extension rod supports 52 may be usedat immediately adjacent or spaced locations.

With the extension rod support 52 positioned as shown at an upper regionof the straight length portion 538, the actuating end 504 issubstantially centered within the conduit assembly 10 ^(4′). Theextension rod support 522 preferably frictionally grips the extensionrod body 512 aggressively enough that the extension rod support 522 willturn with the centered extension rod 500, with the parts 530cooperatively guiding this movement by sliding against an inside surface540 of the conduit part 92 ^(4′).

As noted above, the number of extension rod supports 522 is not limited,nor is the particular construction thereof. Further, different forms ofthe extension rod support 522 may be utilized in association with asingle extension rod 500.

It should be understood that the extension rod support 522 can beutilized with any conduit assembly configuration, as described herein,or otherwise known and devised.

Aside from showing the extension rod supports 522 incorporated, theconduit assemblies 10 ^(5′) in FIGS. 64 and 65 are also of interest asshowing an alternative to the use of the single conduit part 92 ^(4′)extending from the housing 82 ^(4′), as shown in FIGS. 66-68, to theconduit part 90 ^(4′).

The housing 82 ^(4′) may have other shapes, such as cylindrical.

As shown in FIGS. 64 and 65, rather than using a single conduit part 92^(4′), the corresponding conduit part length is made up of separateupper and lower conduit parts 542, 544, respectively, joined by acoupler 546. The conduit parts 542, 544 and coupler 546 may all be madefrom a PVC material, or other materials, or with different materialsmaking up different ones of the parts 542, 544, and coupler 546. Themulti-part construction, among other things, facilitates on-siteadaptation to a particular valve depth.

FIG. 64 also shows a modification wherein the valve base assembly 428,as shown in FIG. 65, is eliminated. It may be difficult or impracticalto incorporate the valve base assembly 428 into a pre-existing systemthat is being repaired and/or modified. The conduit assembly 10 ^(5′)will function otherwise according to the description above, in theabsence of the valve base assembly 428.

In a further modified form of the invention, as shown in FIG. 70, ahousing 82 ^(6′) defines a receptacle 548 for the conduit part 92 ^(4′)or the conduit part 544, depending upon the particular construction,without requiring the separate sleeve/bushing 460, as shown in FIG. 52.

The housing 82 ^(6′), which is preferably, but not required to be, madefrom a urethane material, is molded to define a stop surface/edge 550 toarrest downward movement of the conduit part 92 ^(4′), 544 that abutsthereto. The coupling 460 in the embodiment shown in FIG. 51 defines acorresponding stop surface/edge. Accordingly, downward movement of theconduit part 92 ^(4′), 544 is stopped before the conduit part 92 ^(4′),544 might extend downwardly to interfere with normal operation of thevalve 16 ^(4′). Potentially, in the absence of such a stop surface/edge,downward movement of the conduit part 92 ^(4′), 544 might even inflictdamage upon the valve 16 ^(4′).

The invention also contemplates a variation of the cap as shown at 255′in FIGS. 38-42. As shown in FIGS. 71-75, the modified cap 255 ^(7′) isdesigned to cooperate with conduit pieces, such as the conduit pieces 90^(4′), 240″. The conduit piece 552 is intended to generically encompassthe conduit pieces 90 ^(4′), 240″, and variations thereof.

The cap 255 ^(7′) is snap connected to the conduit piece 552. To effectthis connection, the cap 255 ^(7′) has an annular bead 258 ^(7′) thatcooperates with a complementarily-shaped receptacle 276 ^(7′) formed inthe conduit piece 552.

The bead 258 ^(7′) has a curved outer surface 554 that may beapproximated by an arc with a constant radius.

The cap 255 ^(7′) has a body region 556 below the bead 258 ^(7′) thathas various contours that collectively produce an increasing diameterfrom bottom to top. This overall configuration tends to center the cap255 ^(7′) as it is directed downwardly into the entry opening 274 ^(7′)on the conduit piece 552.

The bead outer surface 554 has a diameter greater than that of theradially inwardly facing surface 558 bounding the entry opening 274^(7′). As downward pressure is applied to the cap 255 ^(7′) duringassembly thereof, the bead 258 ^(7′) is deformed radially inwardly. Oncethe bead 258 ^(7′) aligns axially with the receptacle 276 ^(7′), thebead 258 ^(7′) springs back towards its undeformed state and therebypositively maintains the cap 255 ^(7′) wedged in the closed positionshown in FIGS. 73-75.

With the cap 255 ^(7′) in its closed position, a generally flat uppersurface 560 thereon situates slightly beneath an upper annular edge 562of the conduit piece 552. Thus, it is not apparent to a casual observerhow the cap 255 ^(7′) is maintained in place and how it might beremoved. This deters unauthorized separation of the cap 255 ^(7′).

To facilitate removal for an authorized person, at least one cutout,and, as depicted, a plurality of cutouts/notches 564, is provided in thebody region 556 below the bead 258 ^(7′). The cutouts/notches 564 showneach defines a space to accommodate a prying instrument that may bedirected between the peripheral outer surface 568 on the cap 255 ^(7′)and the surface 558 on the conduit piece 552 to bear against adownwardly facing edge 570 bounding each cutout/notch 564. A force canbe exerted on the prying instrument 566, using the annular edge 562 as afulcrum to bear against the edge 570 to thereby force the cap 255 ^(7′)upwardly, through deformation thereof primarily at the bead region.

Indicia 572 may be provided on the surface 560 to identify the locationof the cutouts/notches 564.

While the invention is operable with a single cutout/notch 564, asdepicted, four such cutouts/notches 564 are provided at regularly spacedintervals around the perimeter of the cap 255 ^(7′).

Preferably, the cap 255 ^(7′) has a non-metal construction to allow therequired deformation to effect assembly and disassembly thereof.Urethane is the preferred material. The cooperating conduit piece 552may be made from any material. If both parts are made from a non-metalmaterial, such as urethane, the above described advantages can berealized. Conduit piece 552 may be metal and will still allow assemblyof the cap 255 ^(7′) as described above and will also afford theadvantage of minimizing corrosion by reason of the non-metalconstruction of the cap 255 ^(7′).

The foregoing disclosure of specific embodiments is intended to beillustrative of the broad concepts comprehended by the invention.

1. In combination: an underground valve for a supply line and having anunderground actuator through which a state of the valve can be changedto control flow within the supply line; and a conduit assembly embeddedin ground material and defining an access passage with a central axisthrough which above ground access can be obtained to the valve actuator,the conduit assembly comprising a housing defining a cavity in which atleast a portion of the valve resides, the conduit assembly furthercomprising a valve base assembly configured to interact with: a) thehousing; and b) at least one of: i) the valve; and ii) the supply lineto maintain a desired relationship between the housing and the at leastone of i) the valve; and ii) the supply line.
 2. The combinationaccording to claim 1 wherein the supply line has a central axis and thehousing and valve base assembly cooperatively extend fully around thecentral axis of the supply line.
 3. The combination according to claim 1wherein the valve base assembly has a curved, upwardly opening seat thatnominally conforms to the at least one of: i) the valve; and ii) thesupply line.
 4. The combination according to claim 1 wherein the housingis made from a urethane material and defines a stop surface/edge and theconduit assembly comprises a first conduit part that is slidableguidingly relative to the housing along the central axis to abut thestop surface/edge.
 5. The combination according to claim 1 wherein thehousing comprises a sleeve and the conduit assembly comprises a firstconduit part that is slidable guidingly against the sleeve along thecentral axis of the access passage.
 6. The combination according toclaim 5 wherein the housing is defined by a base material in which thesleeve is embedded.
 7. The combination according to claim 1 wherein thehousing has an inverted U-shaped receptacle that straddles at least oneof: i) the valve; and ii) the supply line.
 8. The combination accordingto claim 1 wherein the supply line has a central axis and there arecomponents cooperating between the valve base assembly and the at leastone of: i) the valve; and ii) the supply line that are keyed to limitmovement of the valve base assembly relative to the supply line alongthe supply line central axis.
 9. The combination according to claim 5wherein the conduit assembly further comprises a second conduit partthat is telescopingly engaged with the first conduit part.
 10. Thecombination according to claim 9 wherein the housing and first andsecond conduit parts are each made from a non-metal material.
 11. Thecombination according to claim 10 wherein the conduit assembly definesan entry opening to the access passage and the conduit assembly furthercomprises a cap that can be selectively changed between: a) a firststate wherein the cap blocks the entry opening; and b) a second statewherein above ground access can be gained to the valve actuator throughthe entry opening and access passage, wherein the cap is made from anon-metal material.
 12. The combination according to claim 1 wherein theunderground actuator is operated by turning around an axis, thecombination further including an extension rod that extends upwardlyfrom the underground actuator within the access passage and an extensionrod support that is attached to the extension rod and acts against asurface bounding the access passage.
 13. The combination according toclaim 11 wherein the cap has a cutout/notch formed therein configured toreceive a part of a tool that can be used to pry the cap out of itsfirst state.
 14. In combination: an underground valve for a supply lineand having an underground actuator through which a state of the valvecan be changed to control flow within the supply line; and a conduitassembly embedded in ground material and defining an access passage witha central axis through which above ground access can be obtained to thevalve actuator, the conduit assembly comprising a housing defining acavity in which at least a portion of the valve resides, wherein thehousing has an inverted U-shaped receptacle that straddles at least oneof: i) the valve; and ii) the supply line, wherein the housing is madefrom a non-metal material.
 15. The combination according to claim 14wherein the housing is made from urethane and defines a stopsurface/edge and the conduit assembly comprises a first conduit partthat is slidable guidingly relative to the housing along the centralaxis to abut the stop surface/edge.
 16. The combination according toclaim 14 wherein the housing comprises a sleeve and the conduit assemblycomprises a first conduit part that is slidable guidingly against thesleeve along the central axis of the access passage.
 17. The combinationaccording to claim 16 wherein the housing is defined by a base materialin which the sleeve is embedded.
 18. The combination according to claim17 wherein the conduit assembly further comprises a second conduit partthat is telescopingly engaged with the first conduit part.
 19. Thecombination according to claim 18 wherein the housing and first andsecond conduit parts are each made from a non-metal material.
 20. Thecombination according to claim 19 wherein the conduit assembly definesan entry opening to the access passage and the conduit assembly furthercomprises a cap that can be selectively changed between: a) a firststate wherein the cap blocks the entry opening; and b) a second statewherein above ground access can be gained to the valve actuator throughthe entry opening and access passage, wherein the cap is made from anon-metal material.
 21. The combination according to claim 14 whereinthe underground actuator is operated by turning around an axis, thecombination further including an extension rod that extends upwardlyfrom the underground actuator within the access passage and an extensionrod support that is attached to the extension rod and acts against asurface bounding the access passage.
 22. A method of installing aconduit assembly to facilitate controlled access to an actuator on anunderground valve, the method comprising the steps of: providing thecombination of claim 19; repositioning the housing so that the U-shapedreceptacle straddles the at least one of: i) the valve; and ii) thesupply line; sliding one end of the first conduit part against thesleeve along the central axis of the access passage; cutting the firstconduit part at a second location so that the first conduit part has aselected length between the one end and the second location;telescopingly engaging the second conduit part with the first conduitpart so that the first and second conduit parts have a desired combinedlength; and compacting material around the conduit assembly.
 23. Themethod of installing a conduit assembly according to claim 22 whereinthe supply line has a central axis and further comprising the step ofinterconnecting the housing and the at least one of: i) the valve; andii) the supply line so that the housing and the at least one of: i) thevalve; and ii) the supply line are keyed to limit movement of thehousing relative to the supply line along the supply line central axis.